What is Condition-Based Maintenance? The Complete Guide

Condition-Based Maintenance (CBM) is a proactive maintenance strategy that monitors the actual condition of assets to determine when an intervention is necessary. Unlike traditional preventive maintenance, which schedules tasks at regular intervals regardless of asset condition, CBM relies on data collected from sensors, diagnostic tools, and operator rounds to assess equipment health.

Unlike Predictive Maintenance (PdM), which schedules an intervention after detecting an anomaly, CBM plans interventions by considering the equipment’s condition before anomalies or failures occur.

Maintenance actions are triggered only when specific thresholds are exceeded, ensuring efficient resource usage and minimizing downtime. 

What is the difference between PdM & CBM?

To fully understand the differences between Condition-Based Maintenance (CBM) and Predictive Maintenance (PdM), check out our in-depth article that explores their unique features.

Key Features & Components 

Condition-monitoring tools play a critical role in detecting and analyzing equipment conditions to support maintenance decisions: 

• Monitoring tools: Measure key parameters such as temperature, vibration, and heat, providing data about asset performance and health. Examples include infrared thermography, ultrasound, vibration analysis, and oil analysis. These tools help identify wear and degradation early, allowing for timely intervention. 
• There are several types of technologies to gathered data, including wireless and manual sensors or route-based analyzers.   
• Data Acquisition Systems: Collect and process data from various sources, often integrating with systems like CMMS (Computerized Maintenance Management Systems) to organize the information. 
• Analytical Software: Interpret and analyze the collected data to predict maintenance needs using advanced tools like APM (Asset Performance Management) systems.  

What Are the Condition-Based Maintenance Monitoring Techniques (Types of CBM)? 

There are numerous techniques used in condition-based maintenance to monitor equipment health and detect potential issues. Below are some of the most common and widely applied methods: 

• Vibration Analysis: Identifies imbalances, misalignments, or wear in rotating machinery. 
• Infrared Thermography: Detects heat anomalies to identify issues like poor electrical connections or overheating components. 
• Oil Analysis: Monitors lubrication condition and detects contaminants or wear particles.  
• Ultrasound Analysis: Detects high-frequency sounds emitted by issues such as leaks, electrical discharges, or bearing defects. 
• Pressure Monitoring: Measures pressure changes to identify leaks, blockages, or performance inefficiencies in hydraulic or pneumatic systems. 

These methods represent some of the most frequent approaches, but many other specialized techniques exist to address specific needs and equipment types. 

How to Implement a CBM Program? 

Successfully implementing a CBM program involves the following steps: 

1. Asset Selection: Identify critical assets where CBM will deliver the most value. Focus on equipment with high repair costs, long downtimes, or safety-critical operations. 
2. Define Monitoring Parameters: Determine which parameters (e.g., vibration, temperature, or oil quality) are most relevant to the selected assets. 
3. Choose Appropriate Tools: Select monitoring technologies and sensors suitable for the identified parameters and asset types. 
4. Establish Data Collection Methods: Decide on the data acquisition method—whether manual, route-based, or remote systems. 
5. Integrate with Systems: Ensure data integrates into a centralized platform, like a CMMS or APM, for better organization and analysis. 
6. Develop a Maintenance Plan: Use the insights from monitoring to schedule interventions and prioritize tasks effectively. 
7. Train Your Team: Equip your workforce with the skills and knowledge required to use CBM tools and interpret data accurately. 
8. Monitor and Optimize: Continuously review the program’s performance, refine processes, and incorporate feedback to improve results over time. 

Benefits of CBM 

Condition-based maintenance (CBM) offers a range of benefits: 

• Eliminate unnecessary tasks: CBM focuses maintenance efforts only when needed, avoiding redundant activities and saving time. 
• Improved cost efficiency: By reducing unnecessary tasks and unexpected breakdown expenses, CBM lowers overall maintenance costs. 
• Extended equipment lifespan: Timely interventions prevent excessive wear, helping assets last longer. 
• Reduced downtime: Maintenance is performed only as required, minimizing operational disruptions. 
• Optimized resource allocation: CBM prioritizes critical equipment, allowing for more effective and focused use of maintenance resources.

Specific Benefits 

• More Reaction Time: By identifying potential failures early (using the PF curve), CBM allows for timely interventions before catastrophic failure occurs. 
• Non-Intrusive data collection: Monitoring tools gather data without interrupting equipment operations, ensuring minimal disruption. 
• Sensor vs. Route-Based Monitoring: Depending on the asset’s criticality, CBM can use remote sensor for monitoring critical equipment or periodic route-based checks for less critical assets.  

Challenges or Considerations

Initial Setup Costs 

The installation of monitoring tools and software can be expensive, particularly for organizations with a large number of assets. However, the long-term savings often outweigh these initial costs. 

Data Management 

CBM generates a vast amount of data that requires proper systems and expertise to manage and interpret effectively. Without these, organizations may struggle to extract actionable insights. 

Misconceptions 

Some organizations mistakenly believe that CBM is only suitable for large-scale operations. In reality, it can be applied to any industry with critical machinery, regardless of scale. 

Investment in Training 
Implementing a condition-based maintenance program often requires employees to acquire new skills, including understanding advanced monitoring tools and interpreting diagnostic data.  

Advice 

To ensure a smooth implementation, it’s recommended to: 

• Prove the ROI: Start with a small-scale implementation on high-value or mission-critical assets to demonstrate the benefits before scaling up. 
• Scale Gradually: Once the ROI is established, extend CBM across the organization systematically. 

Efficiency and Reliability with CBM 

In conclusion, Condition-Based Maintenance offers a robust framework for maintaining the health of critical assets by using data-driven insights to guide decision-making. While the initial investment in monitoring tools and systems can be significant, the long-term benefits, including cost savings, extended asset lifespans, and reduced downtime, make CBM a valuable strategy for businesses seeking to enhance operational efficiency. With careful implementation and effective data management, CBM can transform maintenance practices, optimizing resource allocation and ensuring a proactive approach to equipment care.

Raphael Tremblay,
Spartakus Technologies
[email protected]